Monday, December 26, 2016

Monday, December 19, 2016

Pouring update

The first pour has hit a trouble. The form got a bit distorted, presumably from the heat of epoxy curing. So, to prevent more distortion, I'm doing the following steps:

1. I'll pour in layers. Each layer produces less pressure, so will distort less. Also, the amount of heat generated by a layer will be easier to dissipate.
2. I'll mix in a lot more sand. It makes the mix harder to pour, to the point where it barely flows if at all, but the amount of heat is again, smaller.
3. I'll add a lot more structure into the forms, so that even if the plastic becomes soft, it will hold shape better.
4. I've added a step at the edges of the leg bases, so even if there is some deformation, it will be hidden away.

To pour in layers, I printed all the parts, so that one batch fills about 3cm of depth. Here are the results of the first batch:

Update: all the XY ends done + small improvement

All the XY ends are printed, ready for installing.
After some thought, I reversed the direction of M8 bolts. Now the bolts sticks from the inside out. This has several advantages:
1. Nothing inside the plastic part has to rotate when I'm tightening  the nuts. So it's much easier to assemble and disassemble.
2. The structure is less sensitive to the bolt size.
3. I think the nylock nuts look way nicer than bolt heads.